4.2.15. Production Readiness Review

DEFENSE ACQUISITION GUIDEBOOK
Chapter 4 -- Systems Engineering

4.2.15. Production Readiness Review

4.2.15. Production Readiness Review

The Production Readiness Review (PRR) for the system determines whether the system design is ready for production, and whether the developer has accomplished adequate production planning for entering Low-Rate Initial Production (LRIP) and Full-Rate Production (FRP). Production readiness increases over time with incremental assessments accomplished at various points in the life cycle of a program.

In the early stages, production readiness assessments should focus on high-level manufacturing concerns such as the need for identifying high-risk and low-yield manufacturing processes or materials, or the requirement for manufacturing development efforts to satisfy design requirements. As the system design matures, the assessments should focus on adequate production planning, facilities allocation, producibility changes, identification and fabrication of tools and test equipment, and long-lead items. The system PRR, held prior to Milestone C, should provide evidence that the system can be produced with low risk and no breaches in cost, schedule, and performance thresholds. See also the System Capability and Manufacturing Process Demonstration described in DoDI 5000.02 Enclosure 2 paragraph 6.c.(6)(d).

For complex systems, a PRR may be conducted for one or more system elements. In addition, periodic production readiness assessments should be conducted during the Engineering and Manufacturing Development phase to identify and mitigate risks as the design progresses. The incremental reviews lead to an overall system PRR. See DAG section 4.2.8. Technical Reviews and Audits Overview for more on this incremental approach.

Roles and Responsibilities

The unique Program Manager responsibilities associated with a system PRR include:

• Approve, fund, and staff the PRR as planned in the Systems Engineering Plan (SEP) developed by the Systems Engineer
• Establish the plan to Physical Configuration Audit (PCA) in applicable contract documents including the SE Management Plan (SEMP), Integrated Master Schedule (IMS), and Integrated Master Plan (IMP)
• Ensure the plan includes independent subject matter experts to participate in each review
• Determine if the readiness of manufacturing processes, quality management system, and production planning (i.e., facilities, tooling and test equipment capacity, personnel development and certification, process documentation, inventory management, supplier management, etc.) provide low-risk assurances for supporting LRIP and FRP
• Continue to control Class I changes to the system product baseline (see DAG section 4.3.7. Configuration Management Process)

The unique Systems Engineer responsibilities associated with a system PRR include:

• Develop and execute the PRR plans with established quantifiable review criteria, carefully tailored to satisfy program objectives
• Ensure that the pre-established review criteria have been met to ensure the production capability forms a satisfactory, affordable, and sustainable basis for proceeding into LRIP and FRP
• Advise the Program Manager on whether production capability forms a satisfactory, affordable, and sustainable basis for proceeding into LRIP and FRP
• Ensure adequate plans and resources are in place to proceed from PRR to PCA and FRP Decision Review (DR)
• Ensure plans to proceed to PCA and FRP DR allow for contingencies
• Ensure production implementation supports overall performance and maintainability requirements
• Monitor and control the execution of the PRR closure plans

Inputs and Review Criteria

Figure 4.2.15.F1 provides the end-to-end perspective and the integration of SE technical reviews and audits across the acquisition life cycle.

Figure 4.2.15.F1. Weapon System Development Life Cycle

The PRR criteria are developed to best support the program’s technical scope and risk and are documented in the program’s SEP no later than Milestone B. Table 4.2.15.T1 defines the suggested PRR products and associated review criteria. The review should not begin until these criteria are considered met and any prior technical review is completed and its action items closed. A readiness assessment tool for PRR preparation is the DoD PRR Checklist. This is a best practice review.

Table 4.2.15.T1. PRR Products and Criteria

A follow-on PRR may be appropriate in the Production and Deployment (PD) phase for the prime contractor and major subcontractors if:

• Changes (from the Engineering and Manufacturing Development (EMD) phase system design) in materials and/or manufacturing processes are required when entering or during the Production and Deployment (P&D) phase
• Production start-up or re-start occurs after a significant shutdown period
• Production start-up is with a new contractor
• The manufacturing site is relocated

The PRR is designed as a system-level preparation tool and should be used for assessing risk as the system transitions from development to FRP. For more information see the approaches described in DAG section 4.3.18.18. Producibility, Quality, and Manufacturing Readiness.

Outputs and Products

The Technical Review Chair determines when the review is complete. Results of the PRR and associated manufacturing readiness assessments are typically documented in a written report or out-brief. The results should be reported based on the criteria documented in the SEP, using the PRR checklist. Another source of information is the Manufacturing Readiness Level Deskbook to be used as appropriate.

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